Textile lubricant and process



United States Patent 2,805,993 TEXTILE LUBRICANT AND PROCESS No Drawing.Application September 29, 1954,

Serial No. 459,199

5 Claims. or. 251-815 The invention relates to textile processing andmore particularly to new and improved lubricants for textile fibers andthe process of applying the same.

It is well-known that in the manufacture of yarns, fabrics, and knitgoods from fibers, whether of vegetable, ammal, mineral or syntheticorigin, oils or oil-containing compositions are generally employed toreduce interfiber friction and thus to facilitate certain operations. a

' The present invention is particularly concerned with the provision ofan improved lubricant for use in'the mechanical operations involved inmaking yarns and threads from fibers.

The utilization of lubricants in'suchprocessing operations may beillustratedby a specific case, that of wool.

In' a conventional process for the manufacture of woolen cloth thescoured stock, either alone or blended with other fibrous'materials, istreated with an oil before it is subjected to any mechanical processing.Such oils should be of a non-resinifying type and preferablyemulsifiable with water either in their own -right or through theaddition of emulsifying agents 'to the oil or to the water. The oil maybe applied in a water emulsion, in a solvent diluent or as the straightoil. The'method of application may be by spray nozzle, by sprinklingcan, or by immersion of the stock in a bath containing the oil dispersedin water or solvent. The stock is then opened and further mixed with theoil by passing through a picker. The oiled fibers are next combed orcarded to paral lelize them and to remove any foreign material. In thecarding operation the fiber lubricant should fulfill the following basicfunctions (1) Reduce interfiber In the combing, Straightening, andparallelizing of fibers during the carding operation the oil facilitatesthe orderly rearrangement of the fibers by reducing interfiber friction.This is reflected in the higher quality of the end product of thecarding operation, which is called roping. The roping will be moreuniform and contain fewer broken fibers as a consequence of thelubricants action. Moreover, the combing action of the card will be moreeflicient and the fibers parallelized to a greater degree in the roping.

(2) Lubricants, in general, reduce the loss during the carding operationof short, linty pieces of fiber to the fioor surrounding 'the cardingmachinery. This waste, besides reducing the potential daily productionof the machine, is a nuisance and an economic loss since it must beswept up and reprocessed. V I v The next operation, spinning, is wherethe roping is drawn and twisted to form the yarn. During the drawing andtwisting, the roping or yarn may break and must be retied beforeproduction resumes. Fiber lubricants reduce this breakage byz" a '1 (l)Producing a more uniform and cohesive roping in the carding operationwhich will inherently spin with fewer breaks. i i

2) Controllinginterfiber friction so that the drawing operation occurswith less breakage;

The'ya'rn is then weveninro' cloth/on" 16ems.- rulin messes PatentedSept. 10, 1957 scouring, dyeing and finishing are operations performedon the woven material before sale, but these operations are notlubricant-dependent except that if not removed by the scour thelubricant would interfere with the dyeing and finishing. The appearanceof the finished material depends, of course, on the efliciency of thelubricant in that a well-lubricated fibrous stock results in a finishedmaterial free of slubs, knots, and other imperfections which can becaused by improper lubricants.

An object of the invention is to provide an improved lubricant for usein the processing of textile fibers.

Another object of the invention is to provide a textile fiberlubricating composition, the lubricity of which is superior to theorganic liquid from which the composition was derived. I

Another object of the invention is to provide a textile lubricant andprocess of the application thereof which results in decreased breakageof yarn during such process- Another object of this invention is toprovide a lubricating composition for textile fibers which reduces thewaste in carding to a greater degree than does the organic liquid fromwhich the composition is derived.

Other objects of this invention will be evident from the furtherdescription of the invention hereinbelow.

In accordance with the invention, an emulsion is provided in which thecontinuous phase is aqueous, and the discontinuous (or dispersed oremulsified) phase is a textile lubricating oil composition comprisingone or more textile lubricating oils with or without emulsifiers and aminor proportion, generally from 5 to 10% by total weight of such oilcomposition, of an organophilic bentonite capable of dispersing with gelformation in organic liquids, all as more particularly hereinafterdescribed and defined.

The fibers, for which the lubricants of the present invention areuseful, may be of vegetable origin such as cotton, linen, ramie, jute,hemp, sisal, and the like; animal fibers such as silk, and mostparticularly animal hair such as wool, camels hair, angora goat hair,and the like; inorganic fibers such as asbestos, glass, and metals;so-called semisynthetic fibers such as rayon, similar celluloseiderivatives, and alginates, and fibers made from proteins such as soyaprotein, zein, and the like; and synthetic fibers such as nylon, variouspolyester fibers such as polyethylene terephthalate (Dacron, Terylene,etc.), various acrylate fibers and others.

. The oily base to which the organophilic bentonitefis added may be asingle oil or a mixture thereof, with or without emulsifying agentsseparately added as needed-in order to insure dispersibility of the oilcomposition in water. Suitable emulsifying agents are well-known;representative agents will be found 'set forth on pp. 411412 of the bookSurface Active Agents by Schwarz and Perry, N. Y. 1949, and pp. 207-210and 213-215 of the book Textilhilfsmittel by A. C-hwala, Vienna, 1939.

The types of oilsused are, of course, well-known. In general, non-dryingoils aroused as otherwise a tendency towards gumming and rancidity'ispresent. Olive oil is widely used, although high in price, and otheroils such as peanut, teaseed and coconut oils are used and also mineraland sulfonated'rnineral oils. The vegetable oils named may likewise besulfonated, particularly where cotton is being processed. So-calledsynthetic lubricating oils such as various polyalkylene glycols,commercially available from the Carbide and Carbon Chemicals Company,may likewise be used. In the case of the sulfonated oils, no emulsifyingagent need be added; but in the-case of some of the oils of feebleself-emulsification properties, either one of the innumerableemulsifying agerit's' available for such purposes may be added in smallproportions, or a sufiicient amount of-one of the self-emulsifyingoilsall as described in Hauser Patent No. 2,531,427. As set forth in thatpatent, a number of different clays may be used and indeed a number ofdifferent organic compounds may. be used in imparting the desiredproperty to the clay mineral. Attention is particularly directed to thesection of the cited Hauser patent beginning at line 44 of column 2 andending at line 31 of column 3, for a general description of applicableorganic onium compounds In the present specification and claims, theterm organophilic bentonite will be used, and it will be understoodthatthis is a comprehensive term for such compounds as are described andclaimed in said Hauser Patent No. 2,531,427, regardless of whetherbentonite itself or an equivalent mineral has been used. Suchorganophilic bentonites have an organic radical, form a gel in anorganic liquid .to which the organic radical of the modified clay has anafiinity, and have a substantial gel characteristic therein. Two gramsor such an organophilic bentonite will swell to at least 20 milliliters,in an excess, for example, 100 milliliters of the liquid, such asnitrobenzene.

Three such organophilicbentonites are commercially obtainable at thepresent'time. They are manufactured by the National Lead Company and aresold as Bentone 18, Bentone 18C, and Bentone 34. Bentone 18 is thereaction product of an octadecyl ammonium halide with a sodium typebentonite; Bentone 18C is the reaction product of a dodecylammoniumhalide with a sodium type bentonite; and Bentone 34 is the reactionproduct of a dimethyl dioctadecylammonium halide with a sodium typebentonite, in both cases the ratio of onium compound to clay being aboutequivalent of the former per 100 grams of the bentonite. They may bedescribed respectively as octadecylammonium bentonite, dodecylammoniumbentonite, and dimethyl dioctadecylammonium bentonite; and they belongto the generic group of organophilic organo-ammonium bentonites. We havefound Bentone 18, Bentone 18C, and Bentone 34 to ,be effective in thepresent invention, and their use therein is particularly convenientsince they are commercially obtainable.

The amount of the organophilic bentonite used in the lubricatingcomposition may vary over wide limits depending upon the propertiesdesired in the final composi-.

tion and may be as high as 25% by weight. However,

i we prefer to use smaller amounts, in the range 0.5 to 10%,

as in this range the improvements resulting from the addition of theorganophilic bentonite are most apparent Without the composition losingthe essential characteristics of the oil in which the organophilicbentonite is incorporated. Five percent is generally both effective andeconomical.

For rapidly accomplishing dispersion of the organ lophilic bentonite inthe organic liquid lubricant it is .often advantageous to heat themixture and pass it through a multiple-roll mill such as a paint millalthough this is not necessary for some combinations.

In the emulsions formed the aqueous phase will generally predominate; infact in the application of textile lubricants of this class generally,it is common to have from about 7 to 25% by volume of oil or oilcomposition in the total volume of emulsion. The exact proportion willdepend upon the type of fiber being processed and the mechanicalequipment being used but it will be found in general that the additionof theorganophilic bentonite to the oil composition in accordance withthe invention will not substantially alter the range of emulsionstrength used.

After the organophilic bentonite is added to the oil composition,particularly as described hereinabove, the

-oil composition containing the organophilic bentonite is a more of theself-emulsifiable sulfonated mineral oil so that the final lubricatingcomposition contained 5 parts dimethyl dioctadecyl ammonium bentonite in95 parts self-emulsifiable mineral oil.

This lubricating composition was stirred into warm water (100160 F.) toform an emulsion and three different concentrations of oil in theemulsion made up.

The proportions of water to oil in the three emulsions were respectively14 to 1, 7 to 1, and 3 to 1. Good dispersion of the lubricatingcomposition in the water was obtained at all ratios, These emulsionswere sprayed on 35 pound lots of scoured wool which were of the type,Texas six months clip wool. The application of emulsion was regulated sothat the amount of lubricating composition applied to the stock was 1.5%(14 to 1 water oil ratio), 3.5% (7 to 1), and 7.0% (3 to 1). In eachcase about 20% water was applied to the wool along with thelubricatingcomposition. As a control, lots of wool of the same type were oiled withthe selfemulsifiable sulfonated mineral oil to which no organophilicbentonite had been added. The lubricant and water were applied in thesame concentrations namely 1.5%, 3.5% and 7.0% oil and in each caseabout 20% water. All percentages were based on the dry weight of thescoured wool. The proportions of oil and water need not be limited tothese ratios.

The superiority of the lubricating composition containing theorganophilic bentonite in the amount 5 parts per 100 parts ofcomposition over the straight oil is apparent from the waste dataobtained on running the 6 lots through the carding machine. All lotswere run under exactly the same conditions and for the same period oftime. These waste figures are presented in Table I below and representthe waste in pounds collected on sheets of paper located at selectedpoints under the machine. Duration of the test was minutes.

TABLE I Carding waste Carding Waste in Pounds A B Lubricant CompositionApplied Parts/100 Parts Wool parts Ratio,

7 Straight Lub., 5 A/B Lubricant parts or- (Control) ganophilicbentonite It is seen that in every case the waste figure is greater forthe straight oil than for the oil containing ,5 parts organophilicbentonite per parts of lubricating comtonite is present averages about20% lower than the control except at the high lubricant levels. This isa significant reduction in waste, particularly where carding is carriedout on a large scale. a a

Further proof of the improved performance of the Inbricant compositioncontaining the organophilic bentonite was found upon measuring thenumber jof breaks encountered in spinning 100 yards of yarn from eachlot of wool. Spinning conditions were identical'for all lots TABLE IIBreaks in spinning Breaks Per 1,000 Yards Spun Lubricant CompositionApplied-Parts/IOO Parts Wool 95 Parts Straight Lubricant, LubricantParts Bentonlte (organophilic) At low lubricant levels the lubricantcomposition containing the bentonite compounds shows a real advantageover the control in the spinning breaks per 100 yards spun. At mediumand higher levels the difierences in breaks are less significant.

Example II.Eighteen parts by weight of the same dimethyl dioctadecylammonium bentonite were added to 82 parts by weight of aself-emulsifiable sulfonated mineral oil and the mixture wasroller-milled twice to disperse the bentonite compound colloidally. Thismixture was then let down with more of the self-emulsifiable mineral oilso that the final lubricating composition contained parts dimethyldioctadecylammonium bentonite in 90 parts self-emulsifiable sulfonatedmineral oil.

This lubricating composition was stirred into warm water (100160 F.) toform an emulsion and three difierent concentrations of oil in theemulsion made up. The proportions of water to oil in the three emulsionswere respectively 14 to 1, 7 to l, 3 to 1. The wool and method ofapplication of the emulsion are identical as in Example I. The amount oflubricating composition applied to the stock was 1.5%, 3.5%, and 7.0%Twenty percent water was applied to each lot along with the lubricant.As a control similar lots of wool were oiled with the self-emulsifiablesulfonated mineral oil to which no organophilic bentonite had beenadded. Oil and water were applied at the same levels namely 1.5%, 3.5%and 7.0% lubricants and 20% water. The proportion of oil and water neednot be limited to these ratios.

The superiority of the lubricating composition containing the bentonitecompound in the amount 10 parts per 100 parts of composition over thestraight oil is apparent from the waste data obtained on running thecomparable lots through the carding machine. All lots were run under thesame machine conditions and for the same time. The waste figures appearin Table III.

TABLE HI Garding Waste in Pounds A B Lubricant Composition App1iedParts/100 Parts Wool 90 Parts Ratio,

Straight Lubricant, A/B Lubricant 10 Parts organophilic bentonite As inExample I, the lubricant composition containing 10 parts organophilicbentonite per 100 parts of lubricating composition ofiers a significantreduction in carding waste.

In the breaks in spinning test, the lubricant composi- 75 mi mhfaining16% philic bentonite again was Superior to the control. Table IVgivesthese results.

TABLE IV Breaks Per 1,000 Yards 7 p Lubricant CompositionApplied-Parts/IOO Parts Wool Parts Straight Lubricant,

Lubricant 10 Parts (Control) Organophilic bentonite At all levels oflubricant addition to the wool, it will be observed that the lubricantcontaining the bentonite compound is markedly superior to the control inpreventing breaks in spinning.

Example IlI.ll0 parts olive oil and parts white mineral oil were blendedtogether and 18 parts of lauryl ammonium bentonite (as commercialBentone 18C) and 5 parts of water were added and mixed by agitation witha high speed propeller type agitator. parts of sodium alkylarylsulphonate (L. Sonneborn Sons Petronate) were added and the stirringcontinued. This mixture was then emulsified with 3600 parts of hot waterusing the same propeller agitator. The resulting emulsion was used inspinning and carding operations on angora goat hair.

Example IV.A sample of attapulgite, taken from near Quincy, Florida, wasfreed from non-clay impurities by subjecting a 17% suspension of theclay dispersed with tetrasodiurn pyrophosphate to high speed agitationby centrifugation. A portion of the suspension containing 62.5 parts ofthe purified attapulgite clay on the dry basis was reacted with a diluteaqueous dispersion of 10 parts of triphenyllauryl phosphonium bromideand the product filtered, Washed, dried and ground. 12 parts by weightof this reacted product were incorporated by milling on a 3 roll paintmill into 100 parts of a sulfonated petroleum oil (Socony-Vacuum Oil Co.Wool- Rex). 8 parts of this oily mixture were emulsified into 92 partsof water by means of a high speed propeller type agitator and theresulting emulsion was used as a fiber lubricant in the spinning ofcotton.

xample V.-7.5 parts of lauryl ammonium bentonite (as commercial Bentone18C) were stirred into 92.5 parts of di-Z ethylhexyl ester of adipicacid (Carbide and Carbons Ucon brand adipate 465) and 50 parts of sodiumalkylaryl sulfonate (L. Sonneborn Sons Petronate) added and this mixturewas emulsified with 1500 parts of hot water. used in spinning operationson long fibered wool.

While in describing the invention specific examples and specificcompounds have been mentioned, it is to be understood that the inventionis a broad one and should be so construed as regards the specificationand the claims hereunto appended.

Having described the invention we claim:

1. The process of lubricating a textile fiber during the forming thereofinto a yarn, which includes the step of bringing the fiber into contactwith an emulsion having a continuous phase of water and a dispersedphase of an oil-organophilic bentonite mixture containing from 0.5% to25% by weight of an organophilic bentonite.

2. The process of lubricating a textile fiber during the forming thereofinto a yarn, which includes the step of bringing the fiber into contactwith an emulsion having a continuous phase of water and a dispersedphase of an oil containing from 0.5% to 25% by weight of an organophilicorgano-ammonium bentonite.

3. The process of lubricating a textile fiber during. the formingthereof into a yarn, which includes the step The resulting stableemulsion was of bringing the fiber into contact with an emulsion havinga'continuo'us; phaseiof Waterthnd a dispersed phase of an oil containingfrom 0.5% to 25% by weight of octadecyl ammonium bentonite.

4. The process of lubricating a textile fiber during the forming thereofinto a yarn, which includes the step of bringing the fiber into contactwith an emulsion having a continuous phase of water and a dispersedphase of an oil containing from 0.5% to 25% by weight of dodecyl'ammonium bentonite,

5. The processof lubricating a textile fiber 'during of an oilcontaining from Q.S to 25% by'weight of 5 dimethyl dioctadecyl ammoniumbentonite.

ReferencesfCited in the fiie of this patent UNITED STATES PATENTS 102,628,197 Killingsworth Feb. 1 1953

1. THE PROCESS OF LUBRICATING A TEXTILE FIBER DURING THE FORMING THEREOFINTO A YARN, WHICH INCLUDES THE STEP OF BRINGING THE FIBER INTO CONTACTWITH AN EMULSION HAVING A CONTINUOUS PHASE OF WATER AND A DISPERSEDPHASE OF AN OIL-ORGANOPHILIC BENTONITE MIXTURE CONTAINING FROM 0.5% TO25% BY WEIGHT OF AN ORGANOPHILIC BENTONITE.